GE ASTAT Plus User Manual

GE Power Controls

SOLID ST A TE

SOFT STARTER

AST A T Plus

USER MANUAL

REMARKS :

1. Read this manual throughly before using the AST AT Plus, and store in a safe place for

reference.

2. Make sure that this manual is delivered to the end user

3. CE Marking

When using AST AT Plus in the EU, compliance with EMC is required.
ASTAT Plus range comply with the generic EN 50081-2 and EN 50082-2

2. The policy of GE Power controls is one of continuous improvement.
The right is reserved to alter the design on any structural details of the products at any
time without giving notice.

ASTAT Plus. Soft Starters

WARNINGS

1. Disconnect power before installing or servicing.

2 Hazardous voltages are present in the motor circuit even when the starter is OFF. An

isolation contactor is recommended, configured to provide automatic isolation when the
motor is turned OFF.

3. Unit may contain more than one live circuit. Disconnect both control and main circuits

before installing or servicing.

4. Soft stop should not be used as an Emergency stop.

5. Stopping mode must be set to meet applicable standards for operator safety.

6. Separate motor overcurrent protection is required to be provided in accordance with the

Canadian Electrical Code, Part 1. ASTAT Plus provides separate motor protection.

CAUTIONS

1. Semi-conductor fuses specified may not provide branch circuit protection. Refer to local

applicable electrical codes.

2. Overload relay setting should be properly coordinated with motor.

3. Slow speed running will affect the motor thermal characteristic due to reduced cooling.

Care must be taken when operating motor under these conditions.

4 DC braking - braking current may cause motor overheating. Select the lowest braking

current and time.

5. DC braking must use additional (DC3) in the motor circuit. See wiring diagram page 6-1.

6. Abnormal starting times in excess of 30 seconds, or closely repeated operations of

acceleration ramp/deceleration ramp, slow speed, or DC injection braking may cause
motor damage. Contact motor manufacturer for proper motor selection.

7. If control power is lost between starts, the overload relay protection is reset to cold start

conditions.

ASTAT Plus. Soft Starters

PRECAUTIONS

1. Debranchez l'alimentation en courant électrique avant de raccorder ou d'intervenir.

2. Des tensions dangereuses sort présente dans le circuit moteur même si le soft starter

indique la position "arrêt". Un contacteur d'isolement assurant un isolement automatique
quand le moteur est arrête, est recommendé.

3. L'appareil peut renfermer plus d'un circuit sous tension de'brancher les circuits principaux

et les circuits de controle avant de raccorder ou d'intervenir.

4. Délestage "soft stop" ne devrait jamais être utilisé en lieu de délestage d'urgence.

5. Procédés de délestage doivent être conforme aux normes de sécurité des utilisateurs.

AVERTISSEMENTS

1. Les fusibles semi-conducteurs specifies ne protégent pas obligatoirement les circuits se

conformer aux codes locaux d'installations électriques.

2. Le relais de courant de surcharge doit être proprement coordonné avec la marche du

moteur.

3. La marche en sous-régime agira sur les caracteristiques thermiques à cause de la

réduction de refroidessement. Opérez le moteur avec précaution dans en ce cas.

4. Ralentissement courant continu peut provoquer la surchauffe de moteur. Choisissez le

plus foible courant de décéleration et la durée de ralentissement la plus courte.

5. Pour freinage courant continu, un contacteur (DC3) additional est nécessaire dans le

circuit moteur, voir le schéma de raccordement page 6-1.

6. Les délais anormaux de mise en service d'une durée supérieure à 30 secondes, ainsi

que les montées/descentes en regime, les exploitations régime lent ou les freinages par
injection de courant continu répétés et rapportes sont suseptibles d'edommager le
moteur. Mettez-vous en rapport avec votre fabricant en ce qui concerne le choix du
moteur adéquat.

7. En cas d'interruption de l'alimentation entre deux dèmarrages, la protection assurée par

démarrage à froid.

8. Le moteur doit être muni d'une protection distincte contre les surintensites, et la

surchauffe conformement au code de l'electricite, premiere partie. ASTAT Plus le relais
de courant de surcharge doit être proprement coordonne avec la marche du moteur.

Section 1. Generalities ................................................................................................................... 1-1

1-1 Comparison of starting systems......................................................................................... 1-1

1-2 Advantages of the AST A T Plus Solid State Soft Starters .................................................... 1-2

Section 2. T ypes and Ratings ....................................................................................................... 2-1

2-1 IEC ratings ........................................................................................................................ 2-1

2-2 UL ratings .......................................................................................................................... 2-2

2-3 Thermal characteristics...................................................................................................... 2-2

Section 3. T echnical specifications............................................................................................... 3-1

3-1 General Specifications....................................................................................................... 3-1

3-2 I/O Terminal Board Specification ....................................................................................... 3-2

3-3 I/O Wiring .......................................................................................................................... 3-3

3-4 Operating modes ............................................................................................................... 3-4

Section 4. Programming. .............................................................................................................. 4-1

4-1 Keypad and display description ......................................................................................... 4-1

4-2 Parameter configuration .................................................................................................... 4-2

4-3 Monitor block parameters................................................................................................... 4-4

4-4 Calibration block parameters ............................................................................................. 4-5

4-5 Basic block parameters ..................................................................................................... 4-6

4-6 Advanced block parameters ............................................................................................... 4-7

Section 5. Installation. ................................................................................................................... 5-1

5-1 Equipment installation ........................................................................................................ 5-1

5-2 Fuses, contactors and supply wiring .................................................................................. 5-2

5-3 Start-up.............................................................................................................................. 5-3

5-4 Troubleshooting.................................................................................................................. 5-3

5-5 Thyristor Check ................................................................................................................. 5-4

Section 6. Appendix....................................................................................................................... 6-1

6-1 Application Diagrams ......................................................................................................... 6-1

6-2 Serial Communications ...................................................................................................... 6-4

6-3 Dimensions........................................................................................................................ 6-12

6.4 PCB's Layout..................................................................................................................... 6-13

i i

INDEX

1-1. Comparison of starting systems

There are numerous applications where soft starting and limited
current peak are needed and thereby making direct starting of
squirrel-cage motors impossible. Traditionally in such cases other
types of starting with reduced stator voltage have been resorted to. The
best-known are star-delta starters, autotransformer starters, stator
resistance starters or using part winding motors.

Any reduced starting voltage imposes a current limitation, and as a
consequence the starting torque is also reduced, but there will always
be peaks during the change from one point or state to another which
can damage the machine being driven. In order to analyse the
performances offered by each of these different types of starters, the
following table shows the special characteristics of each of them,
comparing with the ASTAT system.

Note that in general all reduced voltage starts produce a reduction in
torque in squared proportion to the current in the phases of the motor
(not on the line) and the latter in turn is reduced in linear proportion to
the voltage. From this it can be deduced that any start with reduced
voltage reduces the torque in squared proportion to the voltage per
motor phase. From this point of view soft starting produces, just like any
other reduced voltage start, a reduction in starting torque, according

% of direct start 100% 30 - 40 or 64% 58 - 70% 65% 33% Depending on adjust,
current (in the line) max. 90%

% of direct start torque 100% 30 - 40 or 64% 33 - 49% 48% 33% Depending on adjust,

max. 90%

Starting steps (1) 1 4, 3 or 2 3 or 2 2 2 Continuous, no steps

Connections to motor 33 3 6 6 3

Line overload 5 In 1,5 - 2,1 or 3,2 In 3 - 3,5 In 3,25 In 1,65 In Depending on adjust,
(approx.) max. 4-7 In

Change or NO NO NO NO YES NO
starting pause

(1) "Steps" mean sharp changes of speed during the time from rest until rated speed is reached.

to the adjusted parameters. The advantage, of course, is the ease with
which this ramp can be controlled to produce a soft start in accordance
with the actual requirement of the machine.

From the comparison table it can be seen that the maximum starting
torque attainable using the soft system is 90% of that which direct
starting tends to. Bearing in mind that the direct starting torque varies
between 1.5 and 2.4 times rated torque, it can be deduced that with the
soft starter, starting torques which are somewhat higher than rated are
obtained.

This area includes the starting of pumps, fans, conveyor belts, etc.,
where a torque in the region of 60% of rated is usually sufficient for
correct starting.

As a general rule it can be guaranteed that soft starter will allow starting
of drives which are currently used in conventional starting systems,
with the advantages outlined, and above all the facility to adjust the
current peaks and torque at the machine, faced with the impossibility
or difficulty of varying the steps in conventional systems.

1. Generalities

1-1

CONVENTIONAL STARTERS SOFT STARTER

Direct Autotransfo Stator Part

resistance winding Star-delta

motor

Increase in productivity and reliability with the use of
static soft starters.

1-2. Advantages of the ASTAT Plus Solid State Soft starter

1

Starting and stopping the motor without steps or transitions lengthens the life of
power-driven machine mechanical elements, greatly reducing stress on trans­mission and coupling parts.
Consequently, overhauling times are reduced and machine and facility lifespans
are lengthened.

1. Generalities

1-2

Improvement in acceleration / deceleration
characteristics

2

Being able to start by using the voltage ramp or alternatively by limiting current lets
acceleration fit the load characteristics. Application of a pulse start may also be
selected in cases of high static friction load.
Braking may be made by cutting-off power or by stop ramp, and it is also possible
to brake more energetically by feeding a DC current to the motor stator, so there
are many ways to obtain the best possible deceleration.

This unit can be used for a wide range of applications.
Adjustments are very easy to make and diverse options may be selected to have
equipment capabilities suited to application needs every time.

Easy to run and adjust

6

The signalling code based on alphanumeric display, makes the equipment
working conditions known at any time and gives a quick diagnosis when
protection security is violated.

7

Easy maintanence due to full monitoring

The ASTAT Plus includes advanced functions, like linear acceleration ramp,
forward and reverse jog, programmable I/O or connection to a computer by serial
communication (RS 232), all included as standard.
These performances allows the incorporation of the soft starter to a distributed
control net, in automated plant processes, together with other soft starters,
programmable controllers, variable speed drives, etc.

Pump control

The ASTAT Plus includes a Pump Control function which is more effective than
the standard soft stop, reducing fluid surges or hammering in a pipe line system.
This method reduces the motor speed, by controlling internal parameters in the
motor as well as the output voltage in a close-loop system.

9

The soft starter protects the motor from overloads as well as from incorrect
operating conditions such as loss of an input or output phase, blocked rotor,
thyristor short circuit, etc.

Protected motor

3

Digital technology

4

The control system is based on the use of a highly specialized microcontroller by
which signals are treated digitally, thereby avoiding deratings and adjustments
common to analogue circuits and obtaining excellent precision and speed of
execution.
The control board is made with the technology of surface mounting devices
(SMD), which increases equipment reliability.

5

High level of immunity

Design of the unit was closely tied to the conditions of supply lines, which handle
more disturbance every day. The control signals are optoelectronically isolated
and various levels of protection have been set up in the circuits to immunize the
equipment against external disturbance and its effects.

Advanced functions

8

HEAVY DUTY LIGHT DUTY Degree of TYPE Weight Cooled
Current 220V / 380V / 440V 480V / Current 220V / 380V / 440V 480V / protection unit
rating (2) 240V 415V 500V rating (3) 240V 415V 500V

A kW(4) kW(4) kW(4) kW(4) A kW(5) kW(5) kW(5) kW(5) Kg. Lbs.

14 3 5.5 7.5 - 17 4 7.5 7.5 - IP-00 QC1FDP 4.3 9.48 Natural

3 5.5 7.5 7.5 4 7.5 7.5 11 IP-00 QC2FDP 4.3 9.48 Natural

17 4 7.5 7.5 - 21 5.5 11 11 - IP-00 QC1GDP 4.3 9.48 Natural

4 7.5 7.5 11 5.5 11 11 13 IP-00 QC2GDP 4.3 9.48 Natural

22 5.5 11 11 - 27 7.5 13 15 - IP-00 QC1HDP 4.6 10.14 Natural

5.5 11 11 15 7.5 13 15 15 IP-00 QC2HDP 4.6 10.14 Natural

32 7.5 15 18.5 - 38 10 18.5 22 - IP-00 QC1IDP 4.6 10.14 Natural

7.5 15 18.5 22 10 18.5 22 25 IP-00 QC2IDP 4.6 10.14 Natural

48 13 22 22 - 58 15 25 30 - IP-00 QC1JDP 12.5 27.56 By fan

13 22 2 2 30 15 25 30 37 IP-00 QC2JDP 12.5 27.56 By fan

63 15 30 3 7 - 75 22 37 45 - IP-00 QC1KDP 12.5 27.56 By fan

15 30 3 7 37 22 37 45 45 IP-00 QC2KDP 12.5 27.56 By fan

72 20 37 3 7 - 86 25 45 50 - IP-00 QC1LDP 17.0 37.48 By fan

20 37 3 7 45 25 45 50 50 IP-00 QC2LDP 17.0 37.48 By fan

105 30 55 5 5 - 126 37 63 75 - IP-00 QC1MDP 17.0 37.48 By fan

30 55 5 5 75 37 63 75 80 IP-00 QC2MDP 17.0 37.48 By fan

156 40 75 9 0 - 187 55 90 110 - IP-00 QC1NDP 45.0 99.20 By fan

40 75 9 0 110 55 90 11 0 132 IP-00 QC2NDP 45.0 99.20 By fan

240 63 110 1 32 - 288 80 150 1 65 - IP-00 QC1QDP 45.0 99.20 By fan

63 110 1 32 160 80 1 50 165 20 0 IP-00 QC2QDP 45.0 99.20 By fan

315 90 160 2 00 - 378 110 20 0 2 20 - IP-00 QC1RDP 55.0 121.3 By fan

90 160 2 00 220 11 0 2 00 220 25 0 IP-00 QC2RDP 55.0 121.3 By fan

370 110 20 0 220 - 444 132 2 20 250 - IP-00 QC1SDP 55.0 121.3 By fan

110 20 0 220 250 13 2 220 250 3 15 IP-00 QC2SDP 55.0 121.3 By fan

475 150 25 0 250 - 570 160 3 00 355 - IP-00 QC1TDP 80.0 176.4 By fan

150 25 0 250 335 16 0 300 355 4 00 IP-00 QC2TDP 80.0 176.4 By fan

610 200 31 5 400 - 732 220 4 00 450 - IP-00 QC1UDP 105.0 231.5 By fan

200 31 5 400 400 2 20 400 450 5 00 IP-00 QC2UDP 105.0 231.5 By fan

850 250 450 530 - 1020 300 560 600 - IP-00 QC1VDP 120.0 264.5 By fan

250 45 0 530 600 3 00 560 600 7 50 IP-00 QC2VDP 120.0 264.5 By fan

1075 355 600 670 - 1290 395 715 750 - IP-00 QC1XDP 150.0 330.7 By fan

355 60 0 670 750 3 95 715 750 8 50 IP-00 QC2XDP 150.0 330.7 By fan

2. Types and ratings

2-1

2-1. IEC Ratings (1)

Notes: (1) = Ratings in Amps. given for ambient temperature up to 40ªC and 1000m altitude

Derate output current by 1,5% / ºC above 40ºC.
Derate output current by 1% / 100m above 1000m

(2) = Heavy duty ratings, IEC Class 10 and 20 protections allowed
(3) = Light duty ratings, only IEC Class 10 protection allowed.
(4) = Maximum recommended Motor Power for IEC Class 20 protection. Set ASTAT's parameters "N" and "o" accordingly
(5) = Maximum recommended Motor Power for IEC Class 10 protection. Set ASTAT's parameters "N" and "o" accordingly

2. Types and ratings

2-2

2-2. UL Ratings

Current Max. HEAVY DUTY STANDARD DUTY Degree of TYPE Weight Cooled
rating starting 200V 230V 460V 200V 230V 460V protection (1)

current

A A HP HP HP HP HP HP Kg. Lbs.

14 70 3 3 - 3 3 - IP-00 QC1FDP 4.3 9.48 Natural

- - 7,5 - - 7,5 IP-00 QC2FDP 43 9.48 Natural

17 85 3 3 - 3 3 - IP-00 QC1GDP 4.3 9.48 Natural

- - 10 - - 10 IP-00 QC2GDP 4.3 9.48 Natural

22 110 5 7,5 - 5 7,5 - IP-00 QC1HDP 4.6 10.14 Natural

- - 15 - - 15 IP-00 QC2HDP 4.6 10.14 Natural

34 170 7,5 7,5 - 10 10 - IP-00 QC1IDP 4.6 10.14 Natural

- - 20 - - 25 IP-00 QC2IDP 4.6 10.14 Natural

48 240 10 15 - 15 15 - IP-00 QC1JDP 12.5 27.56 By fan

- - 30 - - 3 0 IP-00 QC2JDP 12.5 27.56

63 3 15 1 5 2 0 - 2 0 20 - IP-00 QC1KDP 12.5 27.56 By fan

- - 40 - - 4 0 IP-00 QC2KDP 12.5 27.56 By fan

72 3 60 2 0 2 0 - 2 0 25 - IP-00 QC1LDP 17.0 37.48 By fan

- - 40 - - 5 0 IP-00 QC2LDP 17.0 37.48 By fan

105 525 30 30 - 30 30 - IP-00 QC1MDP 17.0 37.48 By fan

- - 60 - - 7 5 IP-00 QC2MDP 17.0 37.48 By fan

156 780 40 5 0 - 5 0 60 - IP-00 QC1NDP 45.0 99.20 By fan

- - 100 - - 12 5 IP-00 QC2NDP 45.0 99.20 By fan

240 1200 60 75 - 75 75 - IP-00 QC1QDP 45.0 99.20 By fan

- - 150 - - 20 0 IP-00 QC2QDP 45.0 99.20 By fan

315 1575 75 100 - 100 125 - IP-00 QC1RDP 55.0 121.25 By fan

- - 200 - - 25 0 IP-00 QC2RDP 55.0 121.25 By fan

370 1850 100 125 - 125 150 - IP-00 QC1SDP 55.0 121.25 By fan

- - 250 - - 30 0 IP-00 QC2SDP 55.0 121.25 By fan

500 2500 150 150 - 150 200 - IP-00 QC1TDP 80.0 176.36 By fan

- - 350 - - 40 0 IP-00 QC2TDP 80.0 176.36 By fan

630 3150 200 200 - 200 250 - IP-00 QC1UDP 105.0 231.47 By fan

- - 400 - - 50 0 IP-00 QC2UDP 105.0 231.47 By fan

850 4250 250 300 - 300 350 - IP-00 QC1VDP 120.0 264.54 By fan

- - 600 - - 70 0 IP-00 QC2VDP 120.0 264.54 By fan

2-3. ASTAT Plus, Thermal characteristics

The ASTAT Plus allows motor protection according IEC Class 10 or Class 20 and Nema 10, 20 or 30, free selectable by parameter "o" -overload-

ASTAT-C / CD . Static soft starters

2. Types and ratings

2-3

IEC Class 10 IEC Class 20

Nema 10 Nema 20

Nema 30

Thermal memory:

If the control voltage is not removed, the unit has a cool down charac­teristic, the time for cool down is 300 sec. after the overload trip.
If the control voltage is removed after tripping, you must wait, at least, 2
minutes before the unit can be restarted.

Operations per hour:

Supposing a cycle T, with starting time of t1, running time of T-2t1 at
rated current and OFF time of t1 sec. at least, the ASTAT Plus allows
the following operations per hour.

Starting Operations / Hour. Operations / Hour
Current Starting time t1= 10sec. Starting time t1=20 sec.

Sec.

Ir / In

Sec.

Ir / In

Sec.

Ir / In

Sec.

Ir / In

Sec.

Ir / In

2 Ir 180 90
3 Ir 160 60
4 Ir 30 10

COLD

HOT

COLD

HOT

HOT

COLD

HOT

COLD

HOT

COLD

Voltage Ratings 3ph AC Systems Up to 440V, +10%, -15% for QC1xDP ASTAT Plus series

Up to 500V, +10%, -15% for QC2xDP ASTAT Plus series

Freq. Range 50/60 Hz Control range of 45-65 Hz

Control Control system Digital system with microcontroller
Specifications Starting ramp with progressive increase in voltage and current limitation

Initial voltage (pedestal) % 30 - 95 Un
Starting torque % 10 - 90 M

direct start

Kick start % 95 Un (90% M

direct start

), adjustable 0 to 999 ms
Motor current (Im) 0,4 to 1,2 Ir (rated ASTAT current)
Current limitation 1 to 7 In
Acceleration ramp time s 1 to 99 (types: standard or linear ramp up)
Energy savings Output voltage reduction according to power factor
Override Fixed output voltage permanently equal to supply voltage
Bypass Direct control of a bypass contactor
Brake time by ramp s 1 to 120 (1 to 99 in secondary ramp) adjustable independently of starting ramp time (types: standard,

pump control or linear ramp down)
DC braking 0 to 99 s. ; 0,5 to 2,5In
Slow speed Direct torque: 7% or 14% of nominal speed; reverse torque: 20% of nominal speed
Retry 0 to 4 attemps, and 1 to 99 sec. retry time
Monitoring Motor current, line voltage, power, power factor and elapsed time

Running External control Start - Stop

Acceleration phase Adjustable time
Permanent phase Energy savings / Override choice
Stop phase Power cut-off / Ramp / DC braking/Pump control

Inputs / Outputs Inputs 4 digital optocoupled. Two fixed (Start , Stop) , and 2 programmable (I3, I4)

1 Analog 0-5VDC for Tachogenerator input feedback
Outputs 3 programmable relays, (1r, 2r, 3r)

1 Analog 0-10VDC output for current metering

Protections Current limit Adjustable from 1 In to 7 In

Overload IEC class 10 and 20 ; NEMA class 10,20 and 30 all selectable
Cool-down time after
overload trip s 300 for reset
Loss on input phase s Trip at 3
Thyristor short circuit ms Trip at 200
Heatsink overheating ms Trip at 200
Motor thermistor ms Trip at 200 if thermistor impedance > response value
Loss on output phase s Trip at 3
Stalled rotor ms Trip at 200
Supply frequency error Hz If f < 45 or f > 65, will not start
Overcurrent 100 to 150% In; trip time adjustable from 0 to 99 sec.
Undercurrent 0 to 99% In; trip time adjustable from 0 to 99 sec.
Overvoltage 100 to 130% Un; trip time adjustable from 0 to 99 sec.
Undervoltage 0 to 50% Un; trip time adjustable from 0 to 99 sec.
Error (CPU) ms 60
Memory 4 former errors
Long start time s 2 x ta (ta = acceleration ramp time)
Long slow speed time s 120

Environmental Temperature ºC 0 to +55 (derate output current by 1,5% / ºC above 40ºC)
conditions Relative humidity % 95% without condensation

Maximum altitude m 3000 (derate output current by 1% / 100m above 1000m)
Mounting position Vertical
Protection Degree IP00, UL Open

Standards CE, cUL, UL CE Conforming IEC 947-4-2; UL, cUL conforming to UL508

Conducted & Radiated emissions Conforming IEC 947 -4-2, Class A
Electrostatic discharges Conforming to IEC 1000-4-2, level 3
Radioelectric interference Conforming to IEC 1000-4-6, level 3 and to IEC 1000-4-3, level 3
Immunity to fast trasients Conforming to IEC 1000-4-4, level 3
Immunity to Surge Voltage Conforming to IEC 1000-4-5, level 3

3-1. ASTAT Plus, General specifications

3. Technical specifications

3-1

3. Technical specifications

3-2. I/O terminal board specifications

Power I/O terminals

Terminal Function Description
1L1, 3L2, 5L3 Mains Input 3ph input voltage according ASTAT Plus type.

2T1, 4T2, 6T3 Motor output Output terminals to 3ph AC motor

A1, A2, B1, B2 Input Control Voltage 110/120V AC, +10%, -15%: ; 220/240V AC, +10%, -15%:

Digital Inputs

Terminal Function Description
57 Common for digital inputs This is a common terminal for the digital input terminals specified below.

1 Run Run order. Command signal may be provided by one NO dry momentary contact to terminals 1 and 57.
2 Stop Stop order. Command signal may be provided by one NC dry momentary contact to terminals 2 and 57.

Note: Run/Stop permanent command is allowed linking 1-57 and using one dry NO contact to 2-57

terminals.

3 Programmable input I3 These two inputs are programmable. Can be assigned to the following internal functions
4 Programmable input I4

-soft stop -DC brake -Linear Ramp

-pump control -slow speed control -dual ramp selection

-kick start -reverse slow speed -bypass function

-override -local / remote control

Command signal should be provided by one NC dry contact to terminals 57-3 or terminals 57-4. By switching
this contact ON / OFF it is possible to enable or disable the assigned function.

Digital Outputs

Terminal Function Description
11, 12, 14 Programmable relay1r 11-12 = NC, 11-14 = N.O. dry contacts. This relay can be assigned to several internal output functions. (p. 3.6)

As default assigned to function RUN

23, 24 Programmable relay 2r 23-24 = N.O. dry contact. This relay can be assigned to several internal output functions. (page 3-6)

As default assigned to function EOR

33, 34 Programmable relay 3r 33-34 = N.O. dry contact. This relay can be assigned to several internal output functions. (page 3-6)

As default assigned to function DC BRAKE
Common for all relay output contacts Maximum usage voltage: 380VAC (B300-UL)

Thermal current: 8A.
AC-15 use: 220V / 3A, 380V / 1A
DC-15 use: 30V max/ 3.5A

Analog I/O

Terminal Function Description
8 Analog input common (-) This is a common terminal for the analog input terminal number 7, and analog output termnal number 9.
7 TG feedback input (+) 0-5V analog input for speed feedback. It should be provided by a DC tacho-generator coupled to the motor.

This speed feedback signal is required when the "linear ramp" function is used.

9 Current Output (+) 0-10V DC analog Output for current measurement purpose. Ir correspond to 2V DC

Load Impedance 10KΩ or higher

Motor thermistor terminals

Terminal Function Description
5 , 6 Motor thermistor input This input allows a motor thermistor with a response value from 2,8 to 3,2KΩ , and a reset value from 0,75 to

1KΩ to control motor temperature.
When the motor thermistor is not used, a link must be used in terminals 5-6.

Communications

Terminal Function Description
SG, TD, RD Gr, Tx, Rx data RS232C, 3 wires, half duplex. Maximum cable length 3mts (10 feet)

Asynchronous data transmission, 9600 Bauds, 1 bit start, 8 bits data, 2 bits stop. no parity
ASCII and ModBus RTU protocols selectable from keypad as standard. (Check appendix 6-2)
Profibus DP and DeviceNet by external optional accessory

3-2

3-3. I/O Wiring

3. T echnical specifications

ASTAT Plus's terminal layout and wiring configuration is shown in the diagram of below

(1*)

(1*)

(3*)

(2*)

Notes: (1*) Control and Mains wiring recommendations are given in chapter 5.

(2*) The programmable inputs I3, I4 are not assigned to any function as default. Check pages 3-6 prior to using these inputs.

(3*) The programmable relay outputs are assigned to the following functions as default:

Relay (1r): RUN, (RUN status)
Relay (2r): EOR, (End of Ramp)
Relay (3r): DCBR, (DC Braking control)

(4*) Important: Use dry contacts only

3-3

(4*)

(4*)

3. Technical specifications

3-4

3-4. Operating modes

Initial ramp

Initial voltage (pedestal)

Kick start

Acceleration ramp (t

ramp

)

Current limit

Permanent state

Stopping modes (All selectable)

Override

Energy savings

Starting by voltage ramp

Starting by current limitation

5 main frequncy cycles

30 to 95% Un (adjustable)

95% Un. Enabled by parameter "Pxxx" to ON

Voltage ramp up from1 to 99s (adjustable). Dual ramp possibility

Linear speed ramp by tacho feedback also possible

Fast increase of output voltage when motor gets rated speed

1 to 7 In

Rated voltage (Override)

Rated current

Energy savings. Enabled by "Fxxx" to OFF

Motor power cut-off. "Sxxx" to OFF, "Cxxx" to OFF

Deceleration ramp 1 to 120s (adjustable). Secondary ramp 1 to 99 s

Ramp dowm modes available are:

- Soft Stop -Voltage ramp down-. Enabled by "Sxxx" to ON

- Pump control. Selectable by "Sxxx" to ON and "Cxxx" to ON

- Linear ramp down (Tacho feedback needed)

Evolution of current in deceleration ramp mode

DC brake (0 to 99s adjustable). Enabled by "Bxxx" to ON

Starting and Stopping

1

8

7

6

5a

5

4

3a

2

1a

8a

9

3

Override

Energy savings

3. Technical specifications

3-5

Linear acceleration and deceleration ramp Ramp time adjustable (Selectable by parameter "Dxxx" to ON

Low slow (7%) and High slow (14%) speeds Enabled by parameter "Jxxx" to ON and "jxxx" to LO or HI

Reverse slow speed (20%) Enabled by parameter "Jxxx" to ON and "rxxx" to ON

Slow speed (7% or 14%) Enabled by parameter "Jxxx" to ON

Acceleration ramp Ramp time adjustable

Soft stop (deceleration ramp) Ramp time adjustable

Slow speed (7% or 14%) Enabled by parameter "Jxxx" to ON

DC Brake Current and time adjustables, Enabled by parameter Bxxx to ON, and bxx, Ixxx adjustments

1

8

7

6

5

4

3

2

Linear ramp with T.G. feedback

Slow speed. Basic diagram

Slow speed. Full diagram

1a

3a

Jog and linear ramp

Programmable Inputs and functions

3. Technical specifications

The ASTAT Plus functions like Soft stop, kick start, and etc, can be enabled or disabled by setting ON or OFF in their dedicated parameters, using the facilities
provided by the keypad. Most of these functions can be enabled or disabled remotely as well, through the programmable inputs I3 or I4 (terminals board 3-57 and
4-57).

Soft Stop

Pump Control

Kick Start

Override

By-pass

DC Brake

Linear Ramp

(Jog). Slow Speed

Reverse Jog

Dual motor

Remote Control

S xxx
C xxx
P xxx
F xxx
z xxx
B xxx
D xxx
J xxx
r xxx
A xxx
X xxx

_OFF

_ON

_I3

_I4

Function Parameter

Set Value

The function is permanently disabled

The function is permanently enabled

The status of the function depends on ASTAT's I3 input

The status of the function depends on ASTAT's I4 input

Note: One programmable input may enable or

disable more than one function

<Remarks>

Programmable Relay Outputs

The ASTAT Plus includes three programmable relays 1r, 2r and 3r, (dry contacts). ASTAT terminals are 11-12-14, 23-24 and 33-34
These relays can be assigned to several functions, as shown bellow

Relay 1r

Relay 2r

Relay 3r

20
21
22
23
24
25
26
27
28
29
30

EOR Detects end of voltage ramp. -Only can be asigned to relay 2r­DC Brake DC Brake command -Only can be assigned to relay 3r­Fault Detects ASTAT's fault status
Undervoltage Detects limit set in parameter UVxx
Overvoltage Detects limit set in parameter OVxx
RUN Detects ASTAT's run status
JOG Detects Jog (slow speed) status
Undercurrent Detects limit set in parameter UCxx
Overcurrent Detects limit set in parameter OCxx

Disables the relay function
Future use

Relay N#

Parameter

1r xx

1r xx

3r xx

Set Value

<Remarks>

3-6

More than one function can be enabled in the ASTAT Plus, either by the keypad or through the programmable inputs I3 and I4, but there are some functions
which may not work as expected during stopping, when are simultaneously enabled. The priority when two or more of the below functions are simultaneously
enabled is defined in the following table,

DC Brake (B=ON) l abc

Linear Ramp (S, D=ON) a l aa

Soft Stop (S=ON) b a l c

Pump Control (S, C=ON) c a c l

DC Brake (B=ON)

Linear Ramp (S, D=ON)

Soft Stop (S=ON)

Pump Control (S, C=ON)

a The Unit stops by Linear Ramp
b The unit stops by DC brake after the Soft Stop is completed.
c The unit stops by Pump Control

○○○○○○○○○

○○○○○○○○○

○○○○○○○○○

○○○○○○○○○○○

○○○○○○○○○○○

○○○○○○○○○○○

Condition Action

4-1. Keypad and Display description

1

2

Display

1

F

VVV

F V V V Error code

E01 0 Frequency out of range
E01 1 Overload trip
E01 3 Loss of synchronism
E01 4 Phase U scr
E01 5 Phase V scr
E01 6 Phase W scr
E01 7 Heatsink overtemperature
E01 8 Motor thermistor
E01 9 Phase U lost
E02 0 Phase V lost
E02 1 Phase W lost
E02 2 Stalled rotor
E02 3 Internal error
E02 5 Long start time
E02 6 Long slow speed time
E02 7 Lock-out
E02 8 Undervoltage
E02 9 Overvoltage
E03 0 Undercurrent
E03 1 Overcurrent
E03 2 Retry, attempts exceeded

F V V V Status code

ON Equipment is connected

to main supply
(equipment is ON)

STOP Stop
LOCK Remote stop
PULS Kick start
RAMP Acceleration ramp
FULL Full conduction or

Override

SAVE Energy saving
SOFT Soft stop
PUMP Pump control
DCBK DC braking
INCH Inching / slow speed
TACH Linear ramp (tacho)

Keypad

2

SELECTION

Use with

↑↑

↑↑

↑ or

↓↓

↓↓

↓ to select the parameter or function code to be

displayed and/or modified

SEARCH / ADJUSTMENT

Increases the value of the selected parameter

ENTER / SAVE

- Introduces the new parameter value into memory

- Updates the selected parameter value with the
displayed value

SEARCH / ADJUSTMENT

Decreases the value of the selected parameter

1

14

3

2

0

C/V

Data

Function code

C/V

4-1

4. Programming

Displays Monitoring, Status indications, error messages and function set values

Allows setting of parameters and functions

F F/V V V function code (*)

Mx x x Motor current
vxxx Software Version
. .
. .
PFxx Power Factor
. .
. .
Lxxx Limit current
Txxx Starting Torque
axxx Ramp up time
dxxx Ramp down time
Sxx x Soft Stop selection
..
. .
LKxx Lock out
..
. .

(*) These are examples. Full details in

sections 4-2, 4-3, 4-4, 4-5 and 4-6

Display Structure

4-2. Parameter Blocks configuration

4. Programming

Mode Selection

The ASTAT Plus includes a large number of parameters which are divided in four
blocks: Monitor, Calibration, Basic and Advanced. The parameters of each group can be
displayed or skipped according the selection done in parameter "G".
The monitor parameters are always displayed regardless of the mode selected

Settings in parameter "G" Gxxx The Monitor parameters are always displayed,

whichever are the settings in parameter "G".

GCAL The Calibration parameters are displayed
GBAS The Basic parameters are displayed
GADV The Advanced parameters are displayed
GALL All parameters are displayed

Monitoring
Parameters

Calibration
Parameters

Basic

Parameters

Advanced

Parameters

G CAL

G ALL

G BAS

G ADV

There is a quick way to search automatically the parameter "G" by pressing and Keys. "Gxxx" will be shown on the display.

Once the parameter "G" is displayed, choose the value desired by pressing or Keys. The display will sequence "GBAS", "GCAL", "GADV" and

"GALL" values repeatedly. The actual value displayed can be stored in a temporal memory buffer by pressing key.

Values stored in the temporal memory are lost upon control power loss, unless these are saved in the permanent E2PROM memory through parameter "W".
Additional indications are given in page 4-4

The above is an example given for parameter "G", but all ASTAT Plus parameters can be modified from its default factory value proceeding in similar way.

Searching and Setting Parameters

The ASTAT Plus displays the parameters sequentially while depresing the key and pushing repeteadly or keys.Proceed in this way untill
the parameter "G" is displayed.

C / V

C / V

Parameter layout

Monitor parameters

U

Line Voltage

Voltage Calibration

Unit frame

Current Calibration

t

UF

m

N

Motor rated current

Overload Protection

Service Factor

o

GBAS

Motor Current

Software Version

Line Voltage

Line Power

Elapsed time

Fault history Buffer

Password

E2PROM writting

Parameter Block Selector

M

v

V

w

E

e

K

W

G

f

GADV GALL

GCAL

100-500

F,G ,H , ... ,X

m

40-120

0, N1, N2, N3,C1,C2

100-130

Calibration parameters

e0, e1, e2, e3

12

Status

Shown automatically ON, STOP, LOCK, PULS, ...

(see page 4-4)

C / V

+

4-2

Line Power FactorPF

4. Programming

Ramp up time

Ramp down time

Kick Start

DC Brake time

DC Brake current

Soft Stop switch

Pump Control switch

Kick Start Switch

Override Switch

By-pass Switch

DC Brake Switch

Lock-out

E2PROM Reading

Factory Settings

Retry

Retry time

Undervoltage
Undervoltage trip time

Overvoltage

Overvoltage trip time

Undercurrent

Undercurrent trip time

Overcurrent

Overcurrent trip time

Secondary Ramp up

Secondary Ramp down

Secondary Starting Torque

Tacho control switch

Slow Speed switch

Low / High slow speeds

Reverse slow speed

Dual motor switch

Remote control switch

Output relay 1r

Output relay 2r

Output relay 3r

100-700

010-090

01-99

01-120

000-999

000-099

050-250

OFF, ON, I3, I4

OFF, ON, I3, I4

00-05

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4
PON, PI3, PI4

00-45

ON, OFF

ON, OFF

000-004

001-099

00-50

00-99

00-30

00-99

00-99

00-99

00-50

00-99

01-99

01-99

10-90

ON, OFF, I3, I4

OFF, I3, I4

LO, HI

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4

22-30

20, 22-30

21, 22-30

L

T

a

d

p

b

I

S

C

P

F

z

B

LK

R

Q

Y

y

UV

uv

OV

ov

UC

uc

OC

oc

2a

2d

2t

D

J

j

r

A

X

1r

2r

3r

Basic Parameters

Advanced Parameters

12

4-3

Current Limit

Starting Torque

%

%

sec.

sec.

mS.

sec.

%

Range

Unit

minutes

n. attempts

sec.

%

sec.

%

sec.

%

sec.

%

sec.

sec.

sec.

%

Range

Unit

Pump curve selection
starting

Pump curve selection
stopping

00-03

ST

SP

OFF, ON, I3, I4

Comm Protocol selection

00-02

XP

Station number

001-247

s

4-3. Monitor block Parameters

FunctionDisplay

Status

Motor Current

Software Version

Main Source Voltage

Power Factor

Line Power

Elapsed time

Error trace buffer

Password

E2PROM writting

Parameter display
selection

4. Programming

ON

M xxx

v xxx

V xxx

PFxx

w xxx

E xxx

e xxx

K xxx

W xxx

G xxx

Description

Switch on time. Equipment is connected to main supply
Stop
Remote control through serial port.
Kick start
Acceleration ramp
Full conduction / Override (full voltage)
Energy saving
Soft stop
Pump control
DC braking
Inching / slow speed
Linear ramp (tacho feedback needed)

Displays motor current in Amps.
Current higher than 999A is displayed in kA
If parameter UFxx is not calibrated, the motor current is
displayed in %N

xxx = Version number

Displays line voltage in Volts.

Displays line Power Factor

Displays Line Power

Displays RUN time in Hours (x 1000)

Saves the last four errors
e0xx: Fault 1 -Latest fault- xx: Fault code error
e1xx: Fault 2
e2xx: Fault 3
e3xx: Fault 4

= 69 allows E2PROM writing operation
= 10 Key lock enabled
= 20 Key lock disabled

Saves the unit current parameters to the E2PROM
This rewrites the last values saved

CAL: Displays Calibration Parameters
BAS: Displays Basic Parameters
ADV: Displays Advanced Parameters
ALL: Displays All parameters

Note: The Monitor block parameters are always

displayed

4-4

Default Range Unit

ON
STOP
LOCK
PULS
RAMP
FULL

SAVE

SOFT

PUMP
DCBK

INCH

TACH

000-999

1.0-9.9

-

-

00-99

-

-

e0xx-e3xx

000-999

ON, OFF

CAL, BAS, ADV,

ALL

ON

K 000

W OFF

G BAS

-

-

-

-

-

-

-

-

-

-

-

-

A

kA

%

-

V

%

kW

Hrs

-

-

-

-

4. Programming

4-5

Function

Display Description

Default Range Unit

4-4. Calibration block Parameteres -CAL-

Line Voltage setting

Voltage Calibration

Unit Frame

Current Calibration

Motor Rated Current

Overload Protection

Service Factor

U xxx

t xxx

UF x

m xxx

N xxx

o xxx

f xxx

U 400

t 400

UF 0

m 000

N 100

o C1

f 100

Line Voltage from 100 to 500V. Set rated value

Setting of this parameter allows better accuracy in moni­toring or voltage protections. (Check the voltage calibra­tion procedure)

Unit frame rating (F,G,H,...X)
Setting 0 disables calibration

Setting of this parameter allows better accuracy in moni­toring or current protections. (Check the current calibra­tion procedure)

100 x I motor/ I unit ratio
When this parameter is adjusted at a value higher than
105% the overload protection curve is automatically ad­justed to Class 10. "C1", or to Nema 20 "N2"

Selects either the following overload curves
OFF: Overload protection disabled

(external overload relay must be used)
N1: Nema 10
N2: Nema 20
N3: Nema 30
C1: Class 10
C2: Class 20

Allows motor service factor. Applicable for Nema ratings

100-500

000-600

F, G, H, I, J, K, L,

M, N, Q, R, ...X

000-1000

040-120

OFF

N1, N2, N3,

C1, C2

100-130

V

V

-

A

%

-

%

(*) Voltage calibration procedure

When the unit is installed on site or after PCB's replacement the voltage measurements may have accuracy of 10%. To improve the Voltage
measurement accuracy up to 3% proceed as follow.

1. Switch on the ASTAT and measure the RMS voltage on phases 1L1-3L2 using a calibrated voltmeter

2. Search the parameter "txxx", set the voltage measured and save this value by the key. It is not necessary to rewrite the E2PROM
to make permanent the new setting, the ASTAT plus does this automatically.
NOTE: Set real voltage measured while ASTAT is Power ON. DO NOT enter motor nameplate rating

3. Once the ASTAT has been calibrated, this operation does not need to be repeated. Note however that the parameter "txxx" will show
the latest entry, which may differ from the actual voltage value.

(*) Current calibration procedure

When the unit is installed on site or after PCB's replacement the current measurements may have accuracy of 10%. To improve the Current
measurement accuracy up to 3% proceed as follow.

1. Search parameter "UF x" and enter the right ASTAT's frame type letter. ("F", "G", "H", ..etc.)

2. Start the motor, and measure the rms motor current using a calibrated Ammeter.
This measurement must be done after complete the starting, once the motor current has been stabilized.

3. Search the parameter "mxxx", set the current measured and save this value by the enter's keypad key. It is not necessary to rewrite the
E2PROM to make permanent the new setting, the ASTAT Plus do this automatically.
NOTE: Set real current measured while motor is running. DO NOT enter motor nameplate current rating

4. Once the ASTAT has been calibrated, this operation does not need to be repeated. Note however that the parameter "mxxx" will show
the latest entry, which may differ from the actual current value.

Function

Display Description

Default Range Unit

4-5. Basic block Parameteres. -BAS-

Current Limit

Starting Torque

Ramp Up time

Ramp Down time

Kick start (1)

DC Brake time (1)

DC Brake Current (1)

L xxx

T xx

a xx

d xxx

p xxx

b xx

I xxx

L 350

t 20

a 20

d 020

p 000

b 00

I 050

Sets Device current limit. Sets motor current limit if pa­rameter "N" is properly adjusted.

The maximum range setting is automatically calculated
by the unit according the following expression:

Max Limit = 450 / N (max allowed is 700%)

N is the motor capacity / unit capacity ratio adjusted in
parameter "Nxxx".

Sets the initial voltage applied to the motor

Sets Voltage ramp up time. Motor acceleration time will
depend of load conditions.

Sets Voltage ramp down time. Motor deceleration time
will depend of load conditions.
Enabled only if the parameter "Sxxx" is ON

During the time adjusted, provides 95% of full voltage to
motor at starting time. Useful for high static-friction loads
Enabled only if the parameter "Pxxx" is ON

Provides DC braking at stopping time.
Enabled only if the parameter "Bxxx" is ON

100-700

10-90

01-99

001-120

000-999

00-99

050-250

%

%

sec.

sec.

ms.

sec.

%

4-5-1. Basic Functions

4. Programming

4-6

FunctionDisplay DescriptionDefault Range

4-5-2. Programmable Basic Functions

Soft Stop selector

Pump Control selector

Pump Curve selection
at starting phase

Pump Curve selection
at stopping phase

Kick Start selector

Override selector

S xxx

C xxx

STXX

SPXX

P xxx

F xxx

S OF F

C OF F

ST00

SP02

P OF F

F OF F

Enables or disables all modes of Soft stop

Enables the Pump control function. Usefull to limit fluid hammering.
The parameter "Sxxx" must also be enabled.
NOTE: Parameters "p ", "b " and "I " are disabled while "C" is ON

Choice of various pump control algorithms for starting
00: Voltage ramp up 01-03: Various pump algorithms

Choice of various pump control algorithms for stopping phase
00: Voltage ramp down 01-05: Various pump algorithms

Enables or disables the KIck start function
If Pump control function C is enabled, both Kick start and DC Brake
functions are internally disabled

When this function is enabled, the unit provides constant full voltage
after starting, producing the lowest harmonic distortion. Note that the
energy saving function is disabled when Override is enabled.

OFF, ON, I3, I4

OFF, ON, I3, I4

00-03

00-05

OFF, ON, I3, I4

OFF, ON, I3, I4

Notes:

- Curve 00 (both ST00, SP00): Standard voltage ramp up -starting- and ramp down -soft stop-

- Curve 01 (both ST01, SP01): Pump Algorithm based on estimated average PF -power factor- , with large sampling period

- Curve 02 (both ST02, SP02): Pump Algorithm based on instantaneous PF with short sampling period

- Curve 03 (both ST03, SP03): Pump Algorithm based on estimated average PF with short sampling period

- Curve 04 (SP04): As Curve 3, but with high accuracy on PF average estimation

- Curve 05 (SP05): Pump Algorithm based on former ASTAT CD

4. Programming

4-7

Programmable Basic Functions (follow from previous page)

By-pass selector

DC Brake selector

z xxx

B xxx

z OF F

B OF F

This function provides control of an external by-pass contactor,
significantly lowering heating losses and eliminating harmonics.
When the By-Pass function z is enabled, the programmable relay
output 2r is automatically assigned to this function, and must be used
to control the external by-pass contactor

Enables or disables the DC brake function
When the DC Brake function B is enabled, the programmable relay
output 3r is automatically assigned to this function.
PON, PI3 or PI4 settings enable the DC Brake function just before
starting the motor. This is usefull to stop a fan which is rotating in
reverse at the starting time

OFF, ON, I3, I4

OFF, ON, I3, I4,

PON, PI3, PI4

Function

Display Description

Default Range Unit

4-6. Advanced Block Parameters -ADV-

Lock-Out

E2PROM reading

Factory settings

Retry

Retry time

Undervoltage

Undervoltage trip time

Overvoltage

Overvoltage trip time

Undercurrent

Undercurrent trip time

Overcurrent

Overcurrent trip time

Dual Ramp Up
Dual Ramp Down
Dual StartingTorque

LKxx

R xxx

Q xxx

Y x

y xx

UVxx

uvxx

OVxx

ovxx

UCxx

ucxx

OCxx

ocxx

2axx
2dxx
2Txx

LK00

R OF F

Q OF F

Y 0

y 10

UV00

uv20

OV00

ov20

UC00

uc20

OC00

oc20

2a20
2d20
2T20

Sets time between consecutive starts. Setting "0" disables
this function.

Loads the parameters from the E2PROM to the temporal
buffer

Loads default factory settings to the temporal buffer.

Allows up to four tries of automatic restart after a fault.
Setting 0 disables this function.
Time between retries.

The unit trips if the line voltage decreases below the
percentage set. Setting 0 disables this protection.
Note: Calibrate parameter U before enabling this

protection.

Delay trip time

The unit trips if the line voltage increases above the per­centage set. Setting 0 disables this protection.
Note: Calibrate parameter U before enabling this

protection.

Delay trip time

The unit trips if the current decreases below the percent­age set. Setting 0 disables this protection.
Note: Calibrate parameter U before enabling this

protection.

Delay trip time

The unit trips if the current increases above the percent­age set. Setting 0 disables this protection.
Note: Calibrate parameter U before enabling this

protection.

Delay trip time.

These are a secondary set of ramp up, ramp down and
starting torque parameters, which take over the primary
"a", "d" and "T" when the programmable function A is
enabled.

00-45

ON, OFF

ON, OFF

0-4

01-99

00-50

00-99

00-30

00-99

00-99

00-99

00-50

00-99

01-99
01-99
10-90

min.

-

-

-

sec.

%

sec.

%

sec.

%

sec.

%

sec.

sec.
sec.

%

4-6-1. Advanced Functions

Function

Display

Description

Default Range

4-6-2. Programmable Advanced Functions

Linear Ramp

Slow Speed

Speed changeover

Reverse

Dual motor selector

Remote control selector

Comunication protocol

Station number

D xxx

J xx x

j xx

r xxx

A xxx

X xxx

XPxx

s xxx

D OF F

J OFF

j LO

r OF F

A OF F

X OFF

XP00

s 001

This function provides linear acceleration and deceleration ramps in
a wider range of load conditions using tachogenerator feedback.
A DC Tacho-Generator coupled to motor must be used to provide an
analog signal feedback of 0-5VDC to terminals 7 and 8

This function enables slow speed operation
Maximum operation time 120sec.
LO: Low Speed, 7% of rated speed.
HI: High Speed, 14% of rated speed.
Reverse direction is allowed in "High slow speed" mode only. It
provides 20% of rated speed

This function allows dual motor control settings of acceleration,
deceleration and starting torque, and is useful to start or stop a motor
in diferent load conditions.
When this function is enabled, the parameters 2a, 2d and 2T take
over the parameters a, d and T. It allows dual motor control settings

Allows serial communication control by SG, TD and RD terminals.
Check Appendix section for more details

Sets serialcommunications protocol

0: ASCII 1: Modbus RTU
2: External modules (DeviceNet, ProfibusDP ...)

ASCII protocol allows a maximum of 90 stations only

OFF, ON, I3, I4

OFF, I3, I4

LO, HI

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4

00-02

001-247

Function

Display

Description

Default Range

4-6-3. Programmable Relay Output Functions

Output relay 1r

Output relay 2r

Output relay 3r

1rxx

2rxx

3rxx

1r25

(RUN)

2r20
(EOR)

3r21

(DC Brake)

This is a programmable relay with one NO / NC dry contacts to
ASTAT Plus's terminals 11-12-14

This is a programmable relay with one NO dry contact to ASTAT
Plus's terminals 23-24
This relay is automatically assigned to BY-Pass control if the function
z is ON. Any other assignment by the user is overwrited in this case

This is a programmable relay with one NO dry contact to ASTAT
Plus's terminals 33-34
This relay is automatically assigned to DC-Brake control if the
function B is ON. Any other assignment by the user is overwrited in
this case

22-30

20, 22-30

21, 22-30

The programmable relays can be set to the functions shown in the following table

Function

EOR
DC Brake
FAULT
Undervoltage
Overvoltage
RUN
Slow Speed
Undercurrent
Overcurrent
Disabled
Future use

Remarks

Detects end of voltage ramp. -This function only can be assigned to relay 2r-
DC Brake control command -This function only can be assigned to relay 3r-
Detects unit Fault status. ON is normal status and switches OFF if a fault occurs
Detects Undervoltage according limit adjusted in function UV
Detects Overvoltage according limit adjusted in function OV
Detects unit RUN status
Detects slow speed status
Detects Undercurrent according limit adjusted in function UC
Detects Overcurrent limits as adjusted in function OC
Disables the relay function

Range
20

21
22
23
24
25
26
27
28
29
30

4. Programming

4-8

5-1. Equipment installation

CAUTION! DISCONNECT POWER BEFORE INSTALLING OR SERVICING

ONLY SPECIALIZED PERSONNEL SHOULD INSTALL THE EQUIPMENT AND ONLY AFTER
HAVING READ THIS USER'S GUIDE.

THE USER ITSELF IS RESPONSIBLE FOR ANY PHYSICAL INJURY OR MATERIAL DAMAGE
RESULTING FROM MISHANDLING THE EQUIPMENT.

IF YOU HAVE ANY DOUBTS ABOUT ANY PROCEDURE, PLEASE CONTACT YOUR
DEALER.

Remarks

Supply wire conductors should have the same section as direct starters. As
an indication, Vd voltage drop in wires should not be more than 2%.

Signal wiring should be no longer than 3mts (up to 25mts.when using screened
cable), and should be separate from power wires (line, motor, command relays,
etc.) by at least 10cm, and if they cross, they should do so at a 90º angle

R = conductor resistance (mΩ / m)
L = conductor length (m)
In = motor rated current (A)

Vd =

x R x L x In3

1000

Conductor section (mm2) 2,54 6 1016253550100150
Resistance R (Cu) 20ºC (mΩ / m) 7,5 4,55 3,05 1,85 1,13 0,725 0,528 0,254 0,183 0,122
Resistance R (Al) 20ºC (mΩ / m) 1,86 1,188 0,868 0,416 0,3 0,2

Relays and contactors located in the same housing as the equipment should
have an RC suppressor parallel to the coil (or a reverse diode, if controled by DC).

Do not install capacitors to correct the power factor between equipment
output and motor

If the equipment is fed by a line transformer, its rated power should be at least 1.5
times, but less than 10 times, higher than equipment supply.

AC DC

SIGNAL

POWER

5. Installation

Environment

When installing equipment, keep the following points in mind :

- The equipment should be installed vertically and hang over a platform or
bars. The vertical position is essential for proper cool air circulation

- Environmental conditions are in accordance with the following ranges and
maximum values :

- Operating temperature : 0ºC to +55ºC

- Relative humidity (without condensation) : 95%

- Maximum altitude : 3000m
Reduce rating by 1.5% / ºC from 40ºC and 1% / 100m from 1000m

- Do not install equipment in environments containing explosive or flamma­ble gases, or near important heat sources

- Equipment should be well ventilated, with minimum keeping clearances
as indicated in the illustration.

- When equipment is to be mounted on a platform subject to strong
vibrations, there should be an elastic base to protect the equipment.

150mm

100mm

50mm 50mm

ASTAT

5-1

INCORRECTCORRECT

10 cm 8 cm

5-2. Fuses, contactors and supply wiring

In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor

losses aM FERRAZ type BUSSMANN type DC 1 DC 3 section
100% In (F1) (XX=according (Typower Sicu 660V~) Fuse Consumpt. (2)

Cat Number A W A mech. design) Size In A VA mm

2

QC _ F DP 17 67 25 6,600 CP URC 14.51/40 00 40 1 18 CL02 CL02 4
QC _ G DP 21 78 32 6,6 URD 30 XX 0063 00 50 1 18 CL03 CL03 4
QC _ H DP 27 88 40 6,6 URD 30 XX 0080 00 80 1 18 CL04 CL03 6
QC _ I DP 38 116 63 6,6 URD 30 XX 0100 00 100 1 18 CL45 CL04 10
QC _ J DP 58 208 80 6,6 URD 30 XX 0125 00 125 2 55 CL07 CL45 16
QC _ K DP 75 277 100 6,6 URD 30 XX 0160 00 160 2 55 CL08 CL06 25
QC _ L DP 86 302 125 6,6 URD 30 XX 0160 00 200 2 55 CL09 CL06 35
QC _ M DP 126 389 200 6,6 URD 30 XX 0250 00 250 2 55 CK75 CL07 50
QC _ N DP 187 719 250 6,6 URD 30 XX 0315 00 315 2 78 CK08 CL10 95
QC _ Q DP 288 1097 400 6,6 URD 31 XX 0500 2 550 2 78 CK95 CK85 185
QC _ R DP 378 1286 500 6,6 URD 31 XX 0630 2 630 4 118 CK10 CK85 240
QC _ S DP 444 1374 630 6,6 URD 32 XX 0800 2 800 4 118 CK11 CK95 Bus bar (1)
QC _ T DP 570 2086 800 6,6 URD 33 XX 1000 3 1000 4 118 CK12 CK10 Bus bar (1)
QC _ U DP 732 2352 1000 6,6 URD 33 XX 1250 3 1250 4 248 CK12 CK10 Bus bar (1)
QC _ V DP 1020 3000 1250 6,6 URD 233 XX 2000 - - 4 248 CK13 CK11 Bus bar (1)
QC _ X DP 1290 3839 2x800 6,6 URD 233 XX 2000 - - 4 248 CK13 CK12 Bus bar (1)

5. Installation

In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor

losses aM FERRAZ type BUSSMANN type DC 1 DC 3 section
100% In (F1) (XX=according (Typower Sicu 660V~) Fuse Consumpt. (2)

Cat Number A W A mech. design) Size In A VA mm

2

QC _ F DP 14 56 20 6,600 CP URC 14.51/40 00 40 1 18 CL01 CL01 4
QC _ G DP 17 65 25 6,6 URD 30 XX 0063 00 50 1 18 CL02 CL02 4
QC _ H DP 22 74 32 6,6 URD 30 XX 0080 00 80 1 18 CL03 CL03 4
QC _ I DP 32 99 63 6,6 URD 30 XX 0100 00 100 1 18 CL04 CL04 6
QC _ J DP 48 178 80 6,6 URD 30 XX 0125 00 125 2 55 CL06 CL04 10
QC _ K DP 63 236 80 6,6 URD 30 XX 0160 00 160 2 55 CL07 CL04 16
QC _ L DP 72 257 100 6,6 URD 30 XX 0160 00 200 2 55 CL08 CL06 25
QC _ M DP 105 325 160 6,6 URD 30 XX 0250 00 250 2 55 CL10 CL06 35
QC _ N DP 156 591 200 6,6 URD 30 XX 0315 00 315 2 78 CK75 CL07 70
QC _ Q DP 240 901 315 6,6 URD 31 XX 0500 2 550 2 78 CK85 CK75 120
QC _ R DP 315 1063 400 6,6 URD 31 XX 0630 2 630 4 118 CK95 CK85 185
QC _ S DP 370 1136 500 6,6 URD 32 XX 0800 2 800 4 118 CK10 CK85 240
QC _ T DP 475 1721 630 6,6 URD 33 XX 1000 3 1000 4 118 CK11 CK95 Bus bar (1)
QC _ U DP 610 1950 800 6,6 URD 33 XX 1250 3 1250 4 248 CK12 CK10 Bus bar (1)
QC _ V DP 850 2491 1000 6,6 URD 233 XX 2000 - - 4 248 CK13 CK10 Bus bar (1)
QC _ X DP 1075 3168 1250 6,6 URD 233 XX 2000 - - 4 248 CK13 CK12 Bus bar (1)

(1) As per IEC 947 (2) The 3 contacts of DC3 must be connected in parallel

IEC Class 10
Ratings

5-2

IEC Class 20
Ratings

Max. Fuse Max. Circuit

Type Type Rating Class Breaker Non-

Cat Number A50QS

1

A50P

2

RK5 & J Size Combination Combination <Remarks>

QC _ F DP 50A - 30A 35A 25KA 5KA
QC _ G DP 60A - 35A 40A 25KA 5KA
QC _ H DP 80A - 40A 50A 25KA 5KA
QC _ I DP 100A - 70A 80A 25KA 5KA
QC _ J DP 150A - 100A 125A 25KA 10KA
QC _ K DP 200A - 125A 150A 25KA 10KA
QC _ L DP 225A - 150A 150A 25KA 10KA
QC _ M DP 350A - 200A 250A 25KA 10KA
QC _ N DP 450A - 350A 350A 65KA 25KA
QC _ Q DP 600A - 500A 600A 65KA 25KA
QC _ R DP 2X500A in parallel - 600A 700A 65KA 25KA
QC _ S DP 2x600A in parallel - 600A 800A 65KA 25KA
QC _ T DP - 2x1000A in parallel - 800A 65KA 30KA

*2

QC _ U DP - 2x1200A in parallel - 1000A 65KA 30KA

*2

QC _ V DP - 2x1600A in parallel - 1200A 65KA 65KA

Branch Circuit Protection, UL

Gould-Shawmut, semi-conductor fuses Short-Circuit Rating Max @480V

Note: When ASTAT Plus reduced voltage starters are used in conjunction with semi-conductor fuses, Typen 2 Co-ordination to IEC 947-4 is attained. These

fuses are recommended for best overall short-circuit protection. The semiconductor fuse specified may provide branch circuit protection. Refer to local
applicable electrical codes

(1) Suitable for use on a circuit capable of

delivering not more than 100KA RMS
symetrical amperes, for 208V, 240V and up to
480V maximum, when used with the semi­conductor fuse for short-circuit protection. Listed
with Gould Shawmut Form 101, Type A5QS or
A50P

(2) Suitable for use on a circuit capable of

delivering not more than 65KA RMS symetrical
amperes, for 208V, 240V and up to 480V
maximum, when used with contactors (isolation
or by-pass) that are also rated for 65KA
withstand.

5-3. Start-up

- Make sure equipment wiring corresponds to
one of the recommended routing diagrams or
equivalent

- If the motor has thermal protection sensor, remove the link between terminals
5 and 6 prior to wire the sensor

- Make sure the control wire harness corre­sponds to the control voltage used.

- Adapt equipment rated current to motor, setting
the motor current In

Factory setting

N 1 0 0

N x x x ; x x x =

In (motor)

Ir (unit)

x 100

Factory setting

o C1

oxxx ; xx x OFF = disabled (extermal overload relay must be used

C1/C2 = IEC Class 10 or Class 20
N1/N2/N3= Nema 10, 20 or 30

Factory setting

Starting torque T _ x x T _ 20
Acceleration ramp time a x x x a _ 2 0
Kickstart P ON/OFF/I3/I4 P OFF
Kickstart time p x x x (if P enabled) P 1 0 0
Current limit L x x x L 3 0 0

L x x x =

Im (start)

In (motor)

x 100

Factory setting

Soft stop S ON/OFF/I3/I4 S OFF
Decceleration ramp time d x x x d _ 2 0
DC injection brake B ON/OFF/I3/I4 B OFF
DC braking time b _ x x (if B enabled) b _ _ 5
DC braking current I x x x (if B enabled) I 5 0

- Set braking parameters as needed :

- Set overload trip curve as needed

- Set starting parameters as needed :

- Set parameter K to ON (ON = 69 + )

- Set parameter W to ON

- Press (parameter W is set to OFF automatically)

If you change the default configuration and wish
to keep it, remember to rewrite the parameters
in E2PROM as follows :

- Send run command to equipment and make sure that operation is correct.

110/120V ac

220/240V ac

A1 A1A2 A2B1 B1B2 B2

5. Installation

Display OFF

Symptom or Error Possible Cause Measures to be taken

Check wire harness and control voltage

No control voltage

F1 fuse blown on power supply PCB

Check and change, page 6-8

Verify connectorsBad connection of flat wire joining power

supply PCB to control PCB

F2 fuse blown on power supply PCB

Check and change, page 6-8

Check 1L1 phase and/or mains frequence

No 1L1 phase or frequence is out of range

Excesive load or excesive current during starting

Verify overload conditions during starting time and steady
state.
Check settings in parameters "Nxxx", "Lxxx", and "oxxx"

Overload trip

Equipment does not respond to
STOP / START controls

Frequency error
(admits 45Hz

≤ ≤

≤ ≤

≤ f main

≤ ≤

≤ ≤

≤ 65Hz)

5-4. Troubleshooting

5-3

Symptom or Error & Error Code Possible Cause Measures to be taken

Synchronism loss (Ex13)

Phase U, V, W thyristor (Ex14)

(Ex15)
(Ex16)

Heatsink thermostat (Ex17)

Motor thermistor (Ex18)

Phase U, V, W loss (Ex19)

(Ex20)
(Ex21)

Stalled rotor (Ex22)

Check 1L1 phase

Check thyristor module

Check 2T1, 4T2 and 6T3 phases

No output phases

Shortcircuited thyristor

Phase 1L1 lost

Check thermostat and wiring

Heatsink thermostat tripped by overheating or
defective

Check thermistor and wiring

Motor thermistor tripped by overheating or defective

Check power wire harness for 1L1, 3L2, 5L3,
2T1, 4T2 and 6T3

No input / output phases

Verify gate and cathode wire
harness. Verify thyristors

Defective thyristor or bad wire harness

Restart equipment and check for an appreciable loss in
motor speed at any time (i.e. when the motor is loaded.
In this case, try jumping the bypass terminals 3-57 at the
end of acceleration ramp).

Equipment detected stalled motor rotor

Internal error (Ex23)

Long start time (Ex25)

Long slow speed time (Ex26) Avoid this condition

Equipment has been in slow speed mode more
than 120 sec.

Check IC1 and IC8 are correctly inserted in
their sockets

Microcontroller malfunction

Increase current limit and / or acceleration
ramp time

Current limit condition present more than
2 x ta sec. or 240 sec.
(ta = acceleration ramp time)

5. Installation

S

L

10 ohms

3to6V

3to6V

Testing
lamp

1L1 (3L2 or 5L3)

2T1 (4T2 or 6T3)

5-4

5-5. Thyristor check

Shortcircuit

Use a testing lamp to check the defective power module between input and output phases.
If the lamp goes on, at least one of the thyristors has a shorcircuit.
Check with a tester the value or the R resistance between input and output of the same phase (connector
B on main PCB must be previously removed)
If R < 50KΩ, at least one of the thyristor is defective

Open thyristor

With the simple assembly shown, the lamp should light when the S switch is closed and remain lite when
open.
If not, the thyristor is defective.

Lock-out (Ex27)

Check is settings are correct
This protection may be disabled

The time between startings is less that the
adjusted in parameter "LKxx"

Undervoltage (Ex28)
Overvoltage (Ex29)

Check is settings are correct.
This protection may be disabled

The line voltage exceeds of limit set in
parameters "UVxx" or "OVxx"

Undercurrent (Ex30)
Overcurrent (Ex31)

Check is settings are correct.
This protection may be disabled

The motor current exceeds of limit set in
parameters "UCxx" or "OCxx"

Retry (Ex32)

Check last message "e1xx" and correct.
Be sure that retry settings are correct as well.

The retry feature could not re-start the motor
after a fault

6. Appendix

6-1

6-1. Application diagrams

Basic diagram

REMARKS:
(1) The isolation contactor DC1, is not required to

perform operation to the motor.
Be aware however that DC1 provides galvanic
isolation from the incoming line increasing the safety.

(2) In this example, Start and Stop command is enabled

by push-buttons. Permanent command is allowed as
well, wiring 1, 2 and 57 terminals as shown in page 3-

3.

(3) The output relays allow for direct action on contactors

according ratings specified in page 3-2 of this manual.

(4) The ASTAT Plus is provided with an electronic motor

overload protection, which should be adequate
protection for most of the applications.
You should use an external overload protection if
required by local codes or to protect the motor against
current unbalance.

Basic diagram with By-Pass control

REMARKS:
(1) The isolation contactor DC1, is not re-

quired to perform operation to the motor.
Be aware however that DC1 provides gal­vanic isolation from the incoming line in­creasing the safety.

(2) In this example, Start and Stop command

is enabled by permanent command. Push­buttons control is allowed as well, wiring 1,
2 and 57 terminals as shown in page 3-3.

(3) The output relays allow for direct action on

contactors according ratings specified in
page 3-2 of this manual.

(4) CAUTION:

In by-pass mode an external overload re­lay protection must be used.

(5) By-pass control using function "zxxx" and

external contactor DC2. Details given bel­low.

By-pass control. Programming steps

1. The by-pass function may be enabled by

setting "zxxx" to ON. In this case the by­pass is automatically done after starting.
An alternative, if "zxxx" is set to one of the
programmable inputs "I3" or "I4", the by­pass may be controlled by one remote
signal (5). Check section 4-5-2 for more
details.

2. Once this function is enabled, the relay 2r

is automatically assigned to this function
(check section 4-6-3). This relay must be
used to control the by-pass contactor.

Control Voltage
110 / 120V AC

Control Voltage
220 / 240V AC

Control Voltage

DC1 (1)

DC1

Start Stop
Push Button (2)

Motor Thermistor

FT1 (4)

FT1

(3)

Control Voltage
110 / 120V AC

Control Voltage
220 / 240V AC

Control Voltage

DC1 (1)

DC1

Start /Stop
Permanent
Command (2)

Motor Thermistor

FT1 (4)

DC2

DC2

(3)

FT1

M

3 ~

L1 L2 L3

1 L1 3 L2 5 L3

A1 A2 B1 B2

A1 A2 B1 B2

57 57 57 6 8

12 11 14

23

24

33

34

123 457

2 T1 4 T2 6 T3

9

I3 I4

1r 2r 3r

Programm ab le Inputs

Programm ab le relay Outputs

SG

TD RD

M

3 ~

L1 L2 L3

1 L1 3 L2 5 L 3

A1 A2 B1 B2

A1 A2 B1 B2

57 57 57 6 8

12 11 14

23

24

33

34

123 457

2 T1 4 T2 6 T3

9

I3 I4

1r 2r 3r

Prog r a m ma ble In p uts

Programm able relay Outputs

SG

TD RD

6. Appendix

6-2

6-1. Application diagrams

Basic diagram with jog (slow speed) function

REMARKS:
(1) The isolation contactor DC1, is not required to perform

operation to the motor.
Be aware however that DC1 provides galvanic isolation
from the incoming line increasing the safety.

(2) In this example, Start and Stop command is enabled by

push-buttons. Permanent command is allowed as well,
wiring 1, 2 and 57 terminals as shown in page 3-3.

(3) The output relays allow for direct action on contactors

according ratings specified in page 3-2 of this manual.

(4) The ASTAT Plus is provided with an electronic motor

overload protection, which should be adequate protec­tion for most of the applications.
You should use an external overload protection if
required by local codes or to protect the motor against
current unbalance.

(5) Slow Speed for Jog forward or reverse using programma-

ble inputs I3, I4. Details given bellow.

Jog (Slow Speed) function. Programming steps

1. The slow speed function may be enabled by setting "Jxxx"

to I3. In this case Slow Speed is allowed by a push-button
wired to ASTAT's Plus terminals 3-57.
Reverse jog is also possible by setting "rxxx" to ON. As
alternative, if "rxxx" is set to programmable input I4,
forward or reverse may be controlled by remote push­button signal (5). Check section 4-6-3 for more details.

2. Slow Speed can be effected with ASTAT Plus in stop

status. Slow speed and normal run commands are inter­nally interlocked.

Basic diagram with DC brake injection

REMARKS:
(1) The isolation contactor DC1, is not required to perform

operation to the motor.
Be aware however that DC1 provides galvanic isolation
from the incoming line increasing the safety.

(2) In this example, Start and Stop command is enabled by

permanent command. Push-buttons control is allowed
as well, wiring 1, 2 and 57 terminals as shown in page 3-

3.

(3) The output relays allow for direct action on contactors

according ratings specified in page 3-2 of this manual.

(4) The ASTAT Plus is provided with an electronic motor

overload protection, which should be adequate protec­tion for most of the applications.
You should use an external overload protection if
required by local codes or to protect the motor against
current unbalance.

(5) DC brake at stopping time is provided by the DC brake

function and external contactor DC3.
CAUTION:
The 3 contacts of DC3 must be connected in parallel.
Mandatory between 2T1 and 4T2 phases, otherwise a
short-circuit can occur

DC brake function. Programming steps

1. The DC function may be enabled by setting "Bxxx" to ON.

2. Once this function is enabled, the relay 3r is automatically

assigned to this function. This relay must be used to
control the DC brake contactor.

Check section 4-5-1 and 4-5-2 for more details

Control Voltage
110 / 120V AC

Control Voltage
220 / 240V AC

Control Voltage

DC1 (1)

DC1

Start Stop
Push Button (2)

Motor Thermistor

FT1 (4)

FT1

(3)

Jog Fw/ Rv

Slow Speed (5)

Control Voltage
110 / 120V AC

Control Voltage
220 / 240V AC

Control Voltage

DC1 (1)

DC1

Start /Stop
Permanent
Command (2)

Motor Thermistor

FT1 (4)

DC3

(3)

DC3 (5)

FT1

M

3 ~

L1 L2 L3

1 L1 3 L 2 5 L3

A1 A2 B1 B2

A1 A2 B1 B2

57 57 57 6 8

12 11 14

23

24

33

34

123 457

2 T1 4 T2 6 T3

9

I3 I4

1r 2r 3r

Program mable Inputs

Progr a m m able relay O utpu t s

SG

TD RD

M

3 ~

L1 L2 L3

1 L1 3 L2 5 L3

A1 A2 B1 B2

A1 A2 B1 B2

57 57 57 6 8

12 11 14

23

24

33

34

123 457

2 T1 4 T2 6 T3

9

I3 I4

1r 2r 3r

Programm able Inputs

Programm able relay Outputs

SG

TD RD

6. Appendix

6-3

6-1. Application diagrams

Basic diagram with Linear ramp

REMARKS:
(1) The isolation contactor DC1, is not required to perform

operation to the motor.
Be aware however that DC1 provides galvanic isolation
from the incoming line increasing the safety.

(2) In this example, Start and Stop command is provided by

push-buttons. Permanent command is allowed as well,
wiring 1, 2 and 57 terminals as shown in page 3-3.

(3) The output relays allow for direct action on contactors

according ratings specified in page 3-2 of this manual.

(4) The ASTAT Plus is provided with an electronic motor

overload protection, which should be adequate protec­tion for most of the applications.
You should use an external overload protection if
required by local codes or to protect the motor against
current unbalance.

(5) Linear ramp provided by "Dxxx" function. A tacho genera-

tor must be used as feedback. Details given bellow.

Linear ramp function. Programming steps

1. The linear ramp function may be enabled by setting

"Dxxx" to ON. In this case, linear ramp is independent of
the load.
This function needs the speed feedback provided by an
external tacho generator. Check section 4-6-2 for more
details.

Control Voltage
110 / 120V AC

Control Voltage
220 / 240V AC

Control Voltage

DC1 (1)

Start Stop
Push Button (2)

Motor Thermistor

FT1 (4)

(3)

+-

Linear Ramp (5)

FT1

TG

TAV-5

M

3 ~

L1 L2 L3

1 L1 3 L2 5 L3

A1 A2 B1 B2

A1 A2 B1 B2

57 57 57 6 8

12 11 14

23

24

33

34

123 457

2 T1 4 T2 6 T3

9

I3 I4

1r 2r 3r

Programmable Inputs

Programmable relay Outputs

SG

TD RD

6. Appendix

The following table indicates the communications setting used by Astat Plus to perform data communication via its serial port

Name Setting Description

Baud Rate 9600 bps Bits per second transmission rate
Parity None Data error checking method
Data Bits 8 Number of data bits in each transmission
Start Bits 1 Number of bits to indicate beginning of transmission
Stop Bits 2 Number of bits to indicate ending of transmission
Data ASCII / RTU Communications protocol used
Handshaking None No need to request to send or clear to send

Computer 2 TD ASTAT Plus

Pin

RS232 cable

6-4

6-2. Serial Communication

Astat Plus is able to send and receive data through a serial RS232 port. Within this port Astat Plus communicates with a host (which can be
either with a PC / PLC or an industrial fieldbus system) to be started, stopped, programmed or checked.

3 different communication possibilities are available:

- Connection to a PC / PLC using ASCII protocol. (PC Windows communication software tool available)

- Connection to a PC / PLC using Modbus RTU protocol.

- Connection to industrial fieldbus systems (Profibus DP / DeviceNet). In this case it is necessary to use an external communications
module. Astat Plus communicates with this module using Modbus RTU protocol, and the module acts as a gateway to the fieldbus system.

In order to select the desired procedure the user must change the value of the parameter XP.

Protocol XP setting

ASCII 0
Modbus RTU 1

Profibus/DeviceNet 2

6-2-1. RS232 port, wiring and communications settings

RS232 is an operating standard of communication only in terms of electrical characteristics (voltage, timing, etc.) while the communication
procedures are defined by different protocols (Modbus, ASCII, Profibus, DeviceNet, etc.).
The maximum allowed RS232 cable length is 3 meters. Astat Plus uses a connector with only 3 pins: TD, RD, SG.

Astat Terminal Name

TD Transmit Data
RD Receive Data
SG Signal Common

RS232 connector 3 RD
D-SUB9 5 SG

6-2-2. ASCII Protocol

To select this communications protocol, XP must be set to 0.
It is possible to operate the Astat Plus from a host using standard ASCII characters. Two functions are available to be able to READ and
WRITE parameters.

Write Parameters to ASTAT Plus:

To write data into a parameter, the command format is the following:

Request from host : :ssWxxxyyy

↵↵

↵↵

↵

Response from the ASTAT : :ssWxxxyyy

↵↵

↵↵

↵

where : is a char to indicate the command start, ss is the station address, xxx (3 bytes needed) is the parameter number, and
yyy (3 bytes needed) is the value to write into the parameter. The 

↵↵

↵↵

↵ is the return key to indicate the command stop.

Note: the parameters modification is not allowed while the motor is operating.

Read Parameters from ASTAT Plus:

To read a parameter, the command format is the following:

Request from host : :ssRxxx

↵↵

↵↵

↵

Response from the ASTAT : :ssRxxxyyyyy

↵↵

↵↵

↵

where : is a char to indicate the command start, ss is the station address, xxx (3 bytes needed) is the parameter number, and
yyyyy (5 chars response) is the value of the parameter. The 

↵↵

↵↵

↵ is the return key to indicate the command stop.

Examples:

If we are trying to communicate with station 2:

- to start the unit, the command will be: :02W060000

↵↵

↵↵

↵

- to stop the unit, the command will be: :02W060001

↵↵

↵↵

↵

- to set the acceleration ramp time to 35sec., the command will be: :02W005035

↵↵

↵↵

↵

- to know which overload curve is selected, the command will be: :02R016

↵↵

↵↵

↵ ; ( if, for instance the response is :02R01600004

↵↵

↵↵

↵,

this means that the overload curve selected is IEC class 10 ).

The Table shown in 6-2-5 provides a complete reference for the parameters that can be controlled by the serial interface.

6. Appendix

6-56-5

6-2-3. MODBUS RTU Protocol

Modbus RTU is an standard communication protocol. It is completely predefined, so any Modbus RTU master device will be able to send
and receive data from Astat Plus. To select this communications protocol, XP must be set to 1.

The communication begins with a master request which is answered by the slave (Astat Plus).
Each message from master to slave and viceversa is transmitted asynchronously as follows:

Quiet time Slave Address Function Code Data Field CRC Quiet time

3.5 chars 0-247 1-24 N chars 2 chars 3.5 chars

It is required to give a different address to each slave. A Modbus master is able to handle up to 248 different addresses, but as address 0 is
reserved for broadcast commands, only 247 slaves are allowed. The CRC is an error detection code.
Although Modbus protocol defines up to 24 different functions, only 3 of them will be useful to Astat Plus:

- Read - Write - Read + Write

6. Appendix

6-6

Read Parameters from ASTAT Plus

The function code assigned to Read is 3 (3h).
The request message from master must contain the following information:

- Slave address: the master must indicate which slave has been selected. The non-addressed slaves will receive the message but will
not execute the command. Only the slave with the corresponding address will send a response message.

- Function code: as related above, Read command is number 3.

- Data Field: as this is a read command, the data requested is the number of parameters to be read and the starting address to begin
to read.

Quiet time Slave Address Function Code Data Field CRC Quiet time

starting address

3.5 chars slave # 3 # of parameters 2 chars 3.5 chars

The response from the Astat Plus will contain the same slave address and function code, but the data field will include the total number
of chars read, and the value of the requested parameters.

Quiet time Slave Address Function Code Data Field CRC Quiet time

# of chars read

3.5 chars slave # 3 parameters value 2 chars 3.5 chars

Write Parameters to ASTAT Plus

The function code assigned to Write is 16 (10h).
The request message from master must contain the following information:

- Slave address: the master must indicate which slave has been selected. The non-addressed slaves will receive the message but will
not execute the command. Only the slave with the corresponding address will send a response message.

- Function code: as related above, Write command is number 10h.

- Data Field: as this is a write command, the data requested is the number of parameters to be written, number of chars, starting
address and the value to write.

Quiet time Slave Address Function Code Data Field CRC Quiet time

starting address

3.5 chars slave # 10 # of parameters 2 chars 3.5 chars
# of chars

values to write

The response from the Astat Plus will contain the same slave address and function code, but the data field will include the total number
of chars read, and the value of the requested parameters.

Quiet time Slave Address Function Code Data Field CRC Quiet time

starting address

3.5 chars slave # 10 # of parameters 2 chars 3.5 chars

Read + Write Parameters to ASTAT Plus

The function code assigned to Read and Write is 23 (17h).
The request message from master must contain information to perform both operations:

- Slave address: the master must indicate which slave has been selected. The non-addressed slaves will receive the message but will
not execute the command. Only the slave with the corresponding address will send a response message.

- Function code: as related above, Write command is number 17h.

- Data Field: as a read command, the data requested is the starting address, and the quantity to read. As this is also a write command,
the data requested is the number of parameters to be written, number of chars, starting address and the value to write.

6. Appendix

The response from the Astat Plus will contain the same slave address and function code, but the data field will include the total number
of chars read, and the value of the requested parameters.

Quiet Time Slave Address Function Code Data Field CRC Quit Time

#of chars

3.5 chars slave# 17 parameters read 2 chars 3.5 chars

.

Examples

Supposing we are trying to communicate with slave 17 (note that 17 is 11h):

- To read parameters 3, 4, 5 and 6

Quiet Time Slave Address Function Code Data Field CRC Quit Time

0003

3.5 chars 11 03 0004 2 chars 3.5 chars

- To write values 1, 2 and 3 in parameters 9, 10 and 11

Quiet Time Slave Address Function Code Data Field CRC Quit Time

0009

3.5 chars 11 10 0003 2 chars 3.5 chars
06

0001
0002

0003

-To execute the above 2 commands in one

Quiet Time Slave Address Function Code Data Field CRC Quit Time

0003

3.5 chars 11 17 0004 2 chars 3.5 chars

0009
0003
06
0001
0002
0003

Quiet time Slave Function Code Data Field CRC Quiet

Address time

starting address to read
# of parameters to read

3.5 chars slave 17 #starting address to write 2 chars 3.5 chars

# of parameters to write
# of chars to write

values to write

6-7

6. Appendix

6-2-4. Profibus/ DeviceNet

It is possible to connect Astat Plus to an industrial fieldbus system. Only a communications adapter is required. It is also necessary to set
XP to 2.

2 different modules are available: Profibus DP and DeviceNet.
Profibus DP: Cat. Nr.: QCPPDP Ordering Nr.: 129769
DeviceNet:: Cat. Nr.: QCPDNT Ordering Nr.: 129768
Detailed information about these communications adapter is described in the specific product manuals

Astat Plus communicates with this module using Modbus RTU protocol.

ASTAT Modbus RTU Communications Fieldbus
Plus Adapter System

Profibus DP / DeviceNet

max. length 3m.

The available commands between Astat Plus and the Communications Adapter are the ones described in chapter 4.
All data communication with the ASTAT will be done through the fieldbus input and output data areas in the Communication Adapter, being the
address of these areas the following:

- Input data address (= parameter number): 0000h-0079h (0d-121d), used to read parameters

- Output data address (=1000h+parameter number): 1000h-1079h (4096d-4217d), used to write parameters

Examples:

- to read the T parameter (parameter number: 4), the fieldbus master has to read the address: 4

- to set the T parameter to T045, the fieldbus master has to write the number 45d into the address: 4096+4=4100d (1004h).

- to start the unit (parameter number 60d), the fieldbus master has to write 0 into the address: 4096+60=4156d (103Ch)

- to stop the unit (parameter number 60d), the fieldbus master has to write 1 into the address: 4096+60=4156d (103Ch)

Table in section 6-2-5 includes the complete list of parameters and its description

6-8

Parameter Parameter Function Read/Write Range Comments
number name (R/W)

0 Status Soft starter status R /- 0 - 14 0: ON

1: STOP
2: LOCK
3: Alarm (errors)
4: PULS
5: RAMP
6: FULL
7: SAVE
8: SOFT
9: DCBK
10: FULL (override)
11: Not used
12: INCH
13: TACH
14: PUMP

1 M Motor current R/-

(%N or Amps, depending on UF parameter)
2 N Nominal motor current (% Unit current) R/W 40-120
3 L Limit current (% In) R/W 100-700
4 T Starting torque (% DOL torque) R/W 10-90
5 a Acceleration ramp time (sec) R/W 1-99
6 d Deceleration ramp time (sec) R/W 1-120
7 p Kick start time (msec) R/W 0-999
8 b DC brake time (sec) R/W 0-99
9 I DC brake current (% In) R/W 50-250
10 S Soft stop control R/W 0- 3 0: OFF

1: ON
2: I3
3: I4

11 C Pump control R/W 0-3 0: O FF

1: ON
2: I3
3: I4

12 P Kick start control R/W 0-3 0: OFF

1: ON
2: I3
3: I4

13 F Override R/W 0-3 0: OFF

1: ON
2: I3
3: I4

14 B DC brake control R/W 0-6 0: OFF

1: ON
2: I3
3: I4
4: PON
5: PI3

6:PI4
15 LK Lockout (min.) R/W 0-45
16 o Overload trip curve R/W 0- 5 0: OFF

1: N1

2: N2

3: N3

4: C1

5: C2
17 internal use
18 W Write EEPROM -/W 1
19 R Read EEPROM -/W 1
20  - internal use
21 v Software version R/ - x xx vxxx
22  - internal use
23  - internal use

6. Appendix

6-2-5. List of parameters that can be controlled by the serial interface

6-9

6. Appendix

24 1 r Programmable relay 11-12-14 R/W 22-30 See programmable

relays functions in page 3-6

25 2 r Programmable relay 23-24 R/W 20,22-30
26 3 r Programmable relay 33-34 R/W 21-30
27 OC Overcurrent (%N ) R/W 0-50 0: OFF
28 oc Overcurrent time (sec) R/W 0-99
29 r Reverse slow speed R/W 0-3 0: OFF

1: ON
2: I3

3: I4
30 Y Retry attemps R/W 0-4
31 y Retry time (sec) R/W 1-99
32 UV Undervoltage (%U) R/W 0-50 0: OFF
33 u v Undervoltage time (sec) R/W 0-99
34 OV Overvoltage (%U) R/W 0-30 0: OFF
35 o v Overvoltage time (sec) R/W 0-99
36 UC Undercurrent (%N) R/W 0-99 0: OFF
37 uc Undercurrent time (sec) R/W 0-99
38 PF Power factor (%) R/- 00-99
39 U Nominal voltage (volt) R/W 100-500
40 V Line voltage (volt) R/­41 w Power (KW*10) R /­42 X Local/remote control 0-3 0: OFF

1: ON

2: I3

3: I4
43 D Linear ramp control R/W 0-3 0: OFF

1: ON

2: I3

3: I4
44 J Slow speed control R/W 0 -2 0: OFF

1: I3

2: I4
45 j Slow speed type R/W 0 -1 0: HI

1: LO
46 2a Secondary acceleration ramp time (sec) R/W 1-99
47 2d Secondary deceleration ramp time (sec) R/W 1-99
48 A Dual ramp selection R/W 0-3 0: OFF

1: ON

2: I3

3: I4
49 UF Unit frame R/W 0-16 0: not defined

1 to 16: F to X frames
50 E Elapsed time (hours) R/­51  - internal use
52 Q Recall factory settings -/W 1
53 2T Secondary starting torque (%DOL torque) R/W 10-90
54 m Current calibration R/­55  - internal use
56 z Bypass function R/W 0-3 0: OFF

1: ON

2: I3

3: I4
57  - internal use
58 f Service factor (%N) R/W 100-130
59 t Voltage calibration R/­60 RUN/STOP RUN/STOP order -/W 0: RUN

1: STOP
61  - internal use
62  - internal use
63  - internal use
64  - internal use

Parameter Parameter Function Read/Write Range Comments
number name (R/W)

6-10

65  - internal use
66  - internal use
67  - internal use
68  - internal use
69  - internal use
70 S T Pump Control selection curve R/W 0 -3 0 : standard voltage ramp

1-3 : Pump algorithms

71  - internal use
72  - internal use
73 SP Pump Control selection curve R/W 0-5 0 : standard voltage ramp

1-5 : Pump algorithms
74  - internal use
75  - internal use
76  - internal use
77  - internal use
78  - internal use
79  - internal use
80  - internal use
81  - internal use
82  - internal use
83 XP Communication protocol R/W 0 -2 0 : ASCII

1 : Modbus RTU

2 : others (with external

module)
84 s Station number for communication R/W 1-247
85 e0xx error e0 R/- xx: error code
86 e1xx error e1 R/- xx: error code
87 e2xx error e2 R/- xx: error code
88 e3xx error e3 R/- xx: error code

Parameter Parameter Function Read/Write Range Comments
number name (R/W)

6. Appendix

6-11

6. Appendix

6-12

6-3. Dimensions

QC _ JDP , QC _ KDP QC _ LDP , QC _ MDP

ABC

QC_FDP 200 160 6
QC_GDP 200 160 6
QC_HDP 200 160 6
QC_IDP 250 200 31

170
140

27,5

40

40

32,5

32,5

40

40

27,5

155

Ø7

A

175

B

145

75

100

175

66

C

6-13

6-8. P.C.B. 's

1

1432

0

C/V

ControlSupply

ABCDEFGHI JKL

QC_NDP 510 490 305 460 465 9 53 106 54 259 70 168
QC_QDP 510 490 305 460 465 9 53 106 54 259 70 168
QC_RDP 550 540 317 480 495 9 59 118 54 275 78 168
QC_SDP 550 540 317 480 495 9 59 118 54 275 78 168
QC_TDP 590 685 317 520 640 9 59 118 64,5 270 100 168
QC_UDP 790 850 402 700 805 11 60 120 120 352 120 175
QC_VDP 790 850 402 700 805 11 60 120 120 352 120 175
QC_XDP 810 1000 407 720 955 11 70 140 110 357 120 175

Terminal detail

Terminal

details

QC _ NDP
QC _ QDP

QC _ RDP
QC _ SDP

QC _ TDP A

QC _ UDP 6
QC _ VDP 10

QC _ XDP

6. Appendix

6-3. Dimensions